Formed-container armor structure and methodology

ABSTRACT

A method for forming a ballistic-impact armor structure (and a resulting structure) having a defined, precision-shaped outside configuration, where the method which results in the structure includes the steps of (a) precision-creating a hollow container having the defined outside configuration, (b) introducing ballistic armor-content material into the interior of the container, (c) positionally stabilizing the introduced armor-content material, and (d) unifying the armor-content material with the container.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to currently co-pending U.S.Provisional Patent Application Serial No. 60/691,509, filed Jun. 16,2005, for “Formed-Container Armor Structure and Methodology”. The entiredisclosure content of that provisional application is herebyincorporated herein by reference.

BACKGROUND AND SUMMARY OF THE INVENTION

This invention pertains to ballistic-impact armor structure—specificallyprecision-formed-container armor structure—and to methodology for makingsuch structure.

In today's world, there is much emphasis on, and apparent, or at leastperceived, need for, armoring various spaces, things, vehicles, etc.,for protection against the threat and reality of a ballistic, orrelated, attack. There are many associated environments where this isdesired, and variously, there are strong interests in achievingsuccessful armoring while at the same time doing so: (a) in relativelylight-weight, non-bulky fashion; (b) in a manner which results in astructure that precision-form-fits in relation to a to-be-protectedspace, i.e., a complementary fit-situation; (c) in ways which disguisethe presence of armor, either (1) to deflect attention from the factthat something is being guarded, or (2) to create an estheticallypleasing, faux-appearance, “non-announcement” of the presence of armor,or (3) both of these things; or (d) in other ways which make theplacement of armor more user-friendly and acceptable.

It is also desirable to accomplish some or all of these things inmanners which are simple, versatile, easily deliverable and installable,and relatively inexpensive in all aspects.

The present invention addresses all of these important considerations ina unique methodologic and structural way which is based upon the known,and otherwise used (i.e., in other settings), practice of precisionrotational molding, or roto-molding.

Roto-molding is a process/practice which employs a special kind ofmotion-based molding machinery, or machine, utilizing a pre-formed,precision mold, and associating this mold appropriately with loading,heating, and cooling zones. In such a practice, and if desired, severalmolds may be placed in a roto-molding machine at the same time.Typically, pre-measured plastic resin of selectable character is loadedinto a mold, and the mold is moved into an oven where it is slowlyrotated on both vertical and horizontal axes. Resin introduced into themold before passing of the mold into the oven, and once heated in theoven, melts and sticks to the hot mold interior surface, coating everypart of that surface very evenly. The mold continues to rotate during asubsequent cooling cycle, and as a consequence, each molded componentachieves an even wall thickness, resulting, in accordance with aspecific important feature and practice of the present invention, in ahollow, initially continuous-walled container (i.e., a continuum) havinga specific, precision outside shape and surface characteristic.

This process, i.e., the roto-molding process, enables economicalprecision molding of controlled material, controlled shape, controlledcontinuous wall thickness, and controlled outside surface texture andconfiguration, unitary, hollow, container-like structures, orcontainers, which can then, in accordance with further practice of theinvention, be filled with ballistic armor material, called armor-contentmaterial, which is then suitably stabilized within the hollow interiorof the container.

These important features of the methodology and resulting structure ofthe invention, and how they address ultimately all of the armoringconsiderations expressed earlier herein, will now be more fullypresented as the detailed descriptions thereof which follow below areread in conjunction with the accompanying drawings.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified, isometric, broad-facial illustration of agenerally rectangular, hollow-container, ballistic-impact armor panel,or armor structure, made in accordance with a preferred practice of thepresent invention.

FIG. 2 is an enlarged, fragmentary, partly broken-away, and somewhatmore detailed, schematic edge view of the panel of FIG. 1 with apost-roto-molding, replaceable, removable end portion shown in twodifferent positions. Removal and replacement of this end portion exposesand closes an access opening which accommodates filling of the hollowinterior of the roto-molded container with interior armor material, hereshown to include stabilized, generally parallel-planar layers ofsomewhat different-constituent armoring elements (armor-contentmaterial).

FIG. 3 is an enlarged, fragmentary detail, with portions broken away,taken generally in the region bracketed by curved arrows 3-3 in FIG. 2.

FIG. 4 is a simplified side view of a military vehicle, whereinpanel-like, precision-formed and complementarily shaped armor structure,made in accordance with the present invention, is installed both in adoor, and in a side-panel area, on the side of this vehicle which facesthe viewer in FIG. 4.

FIG. 5 in an enlarged, removed, fragmentary detail of one of the armorpanels installed in the vehicle of FIG. 4, illustrating generally howauxiliary, outside-accessible hardware, such as attaching hardware, maybe molded into the wall of the hollow-container structure portion of thepresent invention. Such hardware is also referred to herein asindependent, relationship hardware—the term “relationship” beingemployed to indicate that such hardware establishes, for example, anappropriate attaching relationship for securing a structure (made bypractice of the present invention) to selected, external “receivingstructure”.

FIG. 6 is somewhat like FIG. 1—showing a panel-like armor structurehaving a quite different perimetral shape.

FIG. 7 is a fragmentary photo-illustration of armor structure made inaccordance with the invention having a container which has beenroto-molded to possess a ballistic-impact strike face formed withthree-dimensional, precision-molded surface structure giving thepredetermined faux appearance of a stone wall.

FIG. 8 is a simplified, schematic view of armor structure including adecidedly non-rectilinear outside shape.

In FIGS. 5, 6 and 8, in relation to FIGS. 1-3, inclusive, commonreference characters are employed to identify generally like structures,like parts thereof, and associated illustration elements.

DETAILED DESCRIPTION OF THE INVENTION

Beginning with FIG. 1-3, inclusive, a generally planar, panel-like,ballistic-impact armor structure 10 made in accordance with a preferredpractice of the present invention is shown. Panel 10, lying generally ina plane 10 a (the plane of FIG. 1) includes a hollow-interior, generallyrectilinear container 12 having a wall 12 a which was initially formedas an uninterrupted, closed-container continuum, by precisionroto-molding, out of a selected plastic resin material in accordancewith conventional roto-molding technique(s), as generally describedearlier herein. While different wall thicknesses may be created asdesired in container 12, wall 12 a herein has a thickness of about⅛-inches. A representative typical range of suitable wall thicknesses,in accordance with practice of the present invention, is from about⅛-inches to about 3/16-inches.

Container 12 may, of course, be formed of any suitable roto-moldingmaterial, and may be shaped/configured in a highly precision-controlledmanner, versatilely and completely by user selection, by pre-formation(in any convention fashion) of an appropriate roto-molding mode. Withrespect to this mold, dimensions, outside surface texture and“topography”, and other features may be designed to be whatever isdesired by a user.

This versatility and user selectability are what enable the making,according to the invention, of a jacketing formed container which can beform-fit complementarily in any one of a number of different userselectable spaces, and which can possess the “outside”esthetic/disguising characteristics which may be desired.

Container 12 herein is formed of cross-linked polyethylene. Other verysuitable plastic resin materials selectable for use in the constructionof a container, such as container 12, may include polyethylene,polypropylene, and high-density polyethylene. A typical molding time forforming such a container might be about 30-minutes. As will becomeapparent, roto-molding of container 12 to finish with what, at leastinitially, is a completely continuous (i.e., a continuum) wall 12 a, isbeneficial to ultimate container integrity, and of course to the economyof container manufacture as well.

Container 12, which lies essentially in previously mentioned plane 10 ahas a hollow interior 12 b which is filled, as will shortly beexplained, with internal ballistic armor-content material 14 (still tobe described) which is introduced into this interior through anysuitable form of access opening, such as an opening created by carefulreturnable removal of a portion of the originally formed container, suchas the portion shown generally at 12 c. Container portion 12 c has beenappropriately divided from the remainder of the container, along aparting line 12 d formed, for example, by sawing. With portion 12 cremoved, line 12 d effectively defines the mentioned access opening tothe interior of the container.

After initial preparation of hollow container 12 by roto-molding, andafter an appropriate portion, such as portion 12 c shown in FIGS. 1 and2, of the container has been removed, preferably returnably, by carefulsawing (or otherwise severing) to expose the inside of the container,insertion and installation of armor material 14, via opening 12 d maytake place generally as indicated (very schematically in FIG. 2) bycurved arrow 15. Such insertion, of course, takes place with containerportion 12 c moved out of the way, as is generally indicated bydouble-headed curved arrow 17, to a suitably displaced position, such asthat shown generally in dashed lines at 12 c in FIG. 2.

Inserted armor-content material, in a structure like panel structure 10,is preferably placed in a manner so that it generally occupies one ormore planes, which plane or planes lie(s) substantially parallel topreviously mentioned plane 10 a. In the specific panel armor structure10 which is illustrated herein, several such layers of armor-contentmaterial are illustrated, including two layers 16 ofside-by-side-adjacent, rectangular, ceramic tiles 16 a, and a pluralityof layers, such as layers 18, formed of aramid-fibre material.

Other materials which may be employed include various highly hardenedsteels, plastic armor sheets, ceramic composites, compressed fibreglas,or other appropriate armor materials of otherwise conventionalconstruction.

These inserted and installed layers of armor-content material areorganized in such a fashion that structure 10 has what is referred toherein as a linear, ballistic-impact response directionality which isillustrated by arrow 20 in FIGS. 1, 2 and 3—i.e., the direction in whichthe structure is preferably oriented to receive any ballistic impact.The “line” of arrow 20 is the line of ballistic-response directionalityherein. In container 12 of structure 10, tiles 16 a are located moreclosely adjacent the “impact-intended” side (the so-called strike-faceside 12 e) of the container than are aramid-fibre layers 18. Strike-faceside, or strike face, 12 e (which, in container 12, is generally planar)extends across the directionality line of arrow 20.

The layer, or layers, of inserted and installed armor-content materialare suitably stabilized on the inside of container 12, with stabilizingmaterial herein shown at 22. In structure 10, material 22 takes the formpreferably of a poured-in high-elastomeric material, such as the productknown as TUFF STUFF® FR made by Rhino Linings USA, Inc. in San Diego,Calif.

Other stabilizing materials which may be used if desired includeexpanded urethane foam, or appropriately driven-in wedges of a material,such as a urethane material. Such a wedge is shown very schematically indashed lines at 24 in FIG. 2.

Following full installation and appropriate stabilizing of armor-contentmaterial 14, removed container portion 12 c, in the particular practiceof the invention now being described, is restored and returned to aposition closing off the interior of the container. It is appropriatelysecured in its returned condition through gluing or heat welding, or inany other appropriate manner. One consideration in this context is thatthis “removed portion” may be re-anchored in position through anappropriate adhesive which offers the opportunity for later removal forinternal panel-structure repairs following a damaging ballistic event.

Describing briefly another container “reclosing” approach, it isentirely acceptable to return “opened” container 12 to a fullyre-enclosed condition by closing off the installation opening in thecontainer with an appropriate cap structure which may not be the portionof the container removed initially to expose the container's interior.

As was mentioned earlier, the roto-molding process which is employed tocreate container 12 in structure 10 offers a great deal of versatilityand selectability in terms of shape and outside surface quality. Forexample, and turning attention for a moment to FIG. 4 in the drawings,here, shown generally at 26 is a military vehicle wherein several panelsmade in accordance with practice of the present invention have beenform-fittingly roto-molded, at least with respect to their containers,for complementary fitment in predefined spaces (preselected receptionspaces) existing in this vehicle. For example, a generally rectangular,panel-like armor structure 28 (seen in dash-dot lines) has beeninstalled form-fittingly, i.e., complementarily, in a preselectedreception door space 30 which exists within a passenger door panel 32located on the side of vehicle 26 that faces the viewer in FIG. 4. Thefit which exists between structure 28 and space 30 is referred to hereinas a complementary utility fit.

Similarly, two somewhat differently perimetrally shaped,container-formed panel-like armor structures, shown by dash-dot lines34, 36, are complementarily fitted into a receiving space (or spaces)firnished in the near side of vehicle 26 in FIG. 4 in the regionimmediately behind door panel 32. Structures 34, 36, which are shownvertically next adjacent one another as illustrated by dash-triple dotline 38, may, if desired, be formed (i.e., roto-molded) simply as asingle structural unit.

As was also mentioned earlier, and turning attention now specifically toFIG. 5 in the drawings, a container-formed armor structure, likestructure 10, may be formed in such as fashion that, during roto-moldingof its container, appropriate externally exposed hardware, such as theattaching hardware shown generally at 40 in FIG. 5, may be molded intothe container wall, such as into container wall 12 a, to be exposedthrough a wall opening, such as the wall opening shown at 12 a ₁ in FIG.5. Attaching structure 40 may be appropriately provided with anchoringstructure, such as that shown at 40 a, which becomes embedded within thematerial forming the container wall.

Such hardware, of any category, may be installed to facilitate securingof an armor structure in place (i.e., to facilitate an attaching“relationship” with external structure), such as might be required withrespect to the several-panel installations shown in FIG. 4 in vehicle26. As was mentioned earlier herein, this hardware, which, strictlyspeaking, is independent of a roto-molded container, per se, is alsoreferred to herein as independent, relationship hardware.

FIG. 6 shows yet another panel-like armor structure 10 having a stillquite different perimetral outline. Reference numerals are employed inFIG. 6, in a manner whereby structural components, and associatedfeatures, that are like those described with respect to FIGS. 1-3,inclusive, are commonly/similarly labeled. Those generally skilled inthe relevant art will appreciate that FIG. 6 is essentiallyself-explanatory.

Turning to FIG. 7 in the drawings, here, shown generally at 42, is apanel-like, ballistic-impact armor structure whose strike face 42 a hasbeen roto-molded to simulate the appearance of a stone wall, includingthe “faux-appearance” look of mortared-together “stone elements”, suchas those shown at 42. FIG. 7 thus provides a very clear illustration ofthe capability of the present invention, in its practice, to enableoutside surface formation in a manner providing an aesthetic and/orotherwise disguising appearance—readily enabled during, and as aconsequence of, the versatile roto-molding approach toward the making ofthe formed container portion of the armor structure of the presentinvention.

FIG. 8 in the drawings, also employing a reference-character scheme likethat used in FIGS. 1-3, inclusive, shows a distinctly non-rectilinear,non panel-like armor structure 10 with a speciallycompoundly-curvedly-shaped, roto-molded container 12 filled withappropriate armor-content material 14. As stated with respect to FIG. 6above, FIG. 8 is also essentially self-explanatory.

From what has been presented above, it will be apparent that one way ofdescribing the methodology of the present invention is to characterizeit as featuring a method for forming a ballistic-impact armor structurehaving a defined, precision shaped outside configuration, with thismethod including the steps of (a) precision-creating a hollow containerhaving the desired, defined outside configuration, (b) introducingballistic armor-content material into the interior of the createdcontainer, (c) positionally stabilizing the introduced armor-contentmaterial, and (d) unifying the armor-content material with thecontainer.

This methodology may be further viewed as one wherein the mentionedprecision-creating step is implemented by precision-roto-molding thecontainer as a closed continuum, and thereafter, in terms of carryingout the introducing step, (1) first providing an access opening in thecontainer continuum, and then (2) implementing the armor-contentintroducing step, per se, by inserting the armor-content materialthrough that access opening.

Thus, a unique formed-container armor structure, and an appropriateroto-molding methodology for container formation, have been illustratedand described herein. They have been described and illustrated in amanner which clearly demonstrates the ability of the present inventionto meet all of the special and important considerations andconcerns/desires of the current state of the art with respect tofurnishing armor structure of the type discussed earlier and aboveherein. Formed-container structures may be created in a very widevariety of sizes, configurations and surface qualities to meet a veryside range of needs.

The preferred roto-molding container-forming process is, as described, aprecision process which enables the construction of armor structures, inaccordance with the present invention, designed to form-fitcomplementarily in a wide variety of differently shaped receivingspaces. Roto-molding offers, in the setting of the present invention,numerous design advantages over other container-forming processes. Theroto-molding process, for example, has a number of inherent designstrengths, such as consistent wall thickness and strong outside cornersthat are virtually stress free. If additional strength is required, forexample in a container to be employed in the present invention,appropriate reinforcing ribs can be designed into such a container.Additives to help make a container weather resistant, flame retardant,or static free can be specified. As suggested, or hinted-at, above,inserts, and other things, such as threads, handles, minor undercuts,flat surfaces that eliminate draft angles or fine surface detail can allbe part of a container's design.

Different specific arrangements and materials may be employed forspecific armor structure components (armor-content materials) which areinserted into the interior of the proposed, roto-molded formedcontainer, with these installed armor components stabilized in any oneof a number of different suitable ways. If desired, an originallycreated access opening provided to the interior of the once (i.e.,initially) continuous-walled container may be closed in such a fashionthat the container may be reopened later if desired to perform internalrepairs after a damaging ballistic event. Armor structures constructedin accordance with the invention are preferably made with a ballisticimpact directionality as mentioned.

Accordingly, while a preferred embodiment of, and manner of practicing,the present invention has been presented herein, and several variationsand modifications have been suggested, it is appreciated that manyvariations and modifications, other than those specifically pointed outherein, may be made without departing from the spirit of the invention.

1. A method for forming a ballistic-impact armor structure having adefined, precision-shaped outside configuration comprisingprecision-creating a hollow container having the defined outsideconfiguration, introducing ballistic armor-content material into theinterior of the container, positionally stabilizing the introducedarmor-content material, and unifying the armor-content material with thecontainer.
 2. The method of claim 1, wherein the armor structure as awhole possesses a linear ballistic-response directionality with respectto an impacting object, and lies generally in a plane which crosses theline associated with the mentioned directionality.
 3. The method ofclaim 1, wherein the armor structure as a whole possesses a linearballistic-response directionality with respect to an impacting object,with the container having been created to include an outwardly exposedstrike face which crosses the line associated with the mentioneddirectionality.
 4. The method of claim 1, wherein the armor structure isintended to have a complementary utility fit within a preselectedreception space, and said precision-creating is carried out in a mannerwhereby the outside configuration of the container complementarily fitssuch space.
 5. The method of claim 1, wherein said precision-creating iscarried out in a manner giving at least a preselected portion of theouter configuration of the container a predetermined faux appearance. 6.The method of claim 5, wherein the predetermined faux appearance resultsfrom an actual, three-dimensional, precision-created surface structure.7. The method of claim 1, wherein said precision-creating is implementedby precision-roto-molding the container as a closed continuum, and whichfurther comprises thereafter (a) providing an access opening in thecontinuum, and (b) implementing said introducing via inserting thearmor-content material through that opening.
 8. The method of claim 7,wherein said providing involves returnably removing a portion of thecontinuum.
 9. The method of claim 1 which further comprises, during saidprecision-creating, introducing independent, relationship hardware so asto result in a precision-created container which is joined to, and whichmakes outwardly accessible, that hardware.
 10. A ballistic-impact armorstructure which is formed in accordance with the methodology of claim 1.11. A ballistic-impact armor structure which is formed in accordancewith the methodology of claim 9.